Thrust plate including cooling slots

ABSTRACT

A thrust plate includes an annular-shaped body having a scalloped outer edge that forms a first circumference defined by a first diameter. The thrust plate further includes a plurality of cooling slots formed in a first surface of the body. The cooling slots are formed between each pair of adjacent scallops. A center of each cooling slot extends towards the center of the thrust plate at a common predetermined angle with respect to one another.

BACKGROUND

The present inventive concept relates generally to an air cycle machine,and more specifically, to a thrust plate included in a bearing coolingsystem of an air cycle machine.

Performance and reliability of a conventional air cycle machine dependson providing proper cooling to one or more thrust bearings included inthe air cycle machine's bearing cooling system. The thrust bearingsupports a rotating assembly included in the bearing cooling system. Athrust plate is provided in the air cycle machine to support the thrustbearing and maintain the axial position of the rotating assembly. As therotating assembly rotates, the thrust bearing may realize an increase inheat. Therefore, the conventional air cycle machine consists only ofvents formed in a containment ring of the air cycle machine housing toflow cool to the thrust bearing.

SUMMARY

According to one embodiment of the present inventive concept, a thrustplate includes an annular-shaped body having a scalloped outer edge thatforms a first circumference defined by a first diameter. The thrustplate further includes a plurality of cooling slots formed in a firstsurface of the body. The cooling slots are formed between each pair ofadjacent scallops. A center of each cooling slot extends towards thecenter of the thrust plate at a common predetermined angle with respectto one another.

According to another embodiment, a method of forming cooling slots in athrust plate comprises defining a horizontal axis that extends radiallyfrom a center of the thrust plate. The method further includes defininga vertical axis that extends radially from the center of the thrustplate, the vertical axis being perpendicular to the horizontal axis. Themethod further includes defining a plurality of leader axes that extendradially from the center of the thrust plate. The plurality of leaderaxes are off-set from at least one of the horizontal and vertical axesby a predetermined angle. The method further includes forming aplurality of slot groupings on a surface of the thrust plate based onthe plurality of leader axes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The subject matter which is regarded as the inventive concept isparticularly pointed out and distinctly claimed in the claims at theconclusion of the specification. The forgoing and other features of theinventive concept are apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings in which:

FIG. 1 is a cross-sectional view of an air cycle machine according to anembodiment;

FIG. 2 illustrates a thrust plate according to at least one embodiment;and

FIGS. 3A-3B are diagrams illustrating dimensions of the thrust plateillustrated in FIG. 2 according to at least one embodiment.

DETAILED DESCRIPTION

Referring to FIG. 1, an air cycle machine (ACM) 10 is illustratedaccording to an embodiment. The ACM 10 includes turbine housing 12 and abearing housing 14. A rotatable shaft 16 extends through the turbinehousing 12 and the bearing housing 14 to drive one or more systems ofthe ACM. The shaft 16 is supported by a first thrust bearing 18 and asecond thrust bearing 20. One or more vents may be formed in the bearinghousing to introduce cool air to the thrust bearings 18, 20. A thrustrunner 22 extends radially outwardly from the shaft 16 to provide extrasupport thereto. A thrust plate 24 is disposed against one side of thesecond thrust bearing 20 to maintain the first and second thrustbearings 18, 20 in place. The thrust plate 24 further includes aplurality of cooling slots to receive air flow. When mounted, theplurality of cooling slots formed on the thrust plate 24 may align witha respective slot formed on a cooling ring of the ACM 10 to form airflow channels that increase the airflow introduced to the thrustbearings 18, 20.

Referring now to FIG. 2, a thrust plate 24 is illustrated according toan embodiment. The thrust plate 24 includes an annular shaped body 26having a first surface 28 and a second surface 30 opposite the firstsurface. The body 26 includes a scalloped outer edge, which reduces theoverall weight of the thrust plate 24. The scalloped outer edge forms afirst circumference defined by a first diameter being approximately3.860 inches (approximately 9.804 cm) and an inner edge forming a secondcircumference defined by diameter being approximately 1.218 inches(approximately 3.094 cm). The scalloped outer edge defines a pluralityof curved scallops 32, i.e., projections, spaced apart from one anotherby a gap 34. At least three of the gaps are sized larger than theremaining gaps 34 to define an alignment gap 34′, which positions thethrust plate 24 at a predetermined orientation when the thrust plate 24is coupled to the turbine housing and the bearing housing.

Each individual scallop 32 includes an outer eyelet 36 formedtherethrough. In at least one embodiment, a first plurality of the outereyelets 36 has a first eyelet diameter of approximately 0.170 inches(approximately 0.432 cm) to receive a respective first bolt, whichcouples a first portion of the thrust plate to the turbine housing ofthe ACM 10. A second plurality of the outer eyelets 36′ has a secondeyelet diameter of approximately 0.145 inches (approximately 0.368 cm).The second diameter receives a respective second bolt to couple a secondportion of the thrust plate 24 to the bearing housing of the ACM 10. Thealignment gaps 34′ assist in positioning the thrust plate 24 at apredetermined orientation when coupled to the turbine housing and thebearing housing via the bolts. That is, the alignment gaps 34′ assistingin preventing the thrust plate 24 from being improperly assembled. Thethrust plate 24 further includes a plurality of alignment holes 38 toreceive a respective pin to be disposed therethrough. Each alignmenthole 38 is formed adjacent a respective gap 34 to further promote thealignment of the thrust plate 24 with respect to the turbine housing andthe thrust bearing housing.

The thrust plate 24 further includes by a plurality of cooling slots 40formed in the first surface 28. In at least one embodiment illustratedin FIG. 2, the thrust plate 24 includes 10 cooling slots 40 arrangedaccording to a plurality of slot groupings. In at least one embodiment,first and second slot groupings each consist of four cooling slots 40and a third slot grouping consists of two cooling slots 40. Each coolingslot 40 is formed between a pair of adjacent scallops 32 and extendsbetween an open end formed at the outer edge of the thrust plate 24 anda curved end. Each cooling slot 40 has a length ranging fromapproximately 0.3 inches (approximately 0.762 cm) to approximately 0.4inches (approximately 1.016 cm). Further, each cooling slot 40 has awidth (w) ranging from approximately 0.155 inches (approximately 0.394cm) to approximately 0.165 inches (approximately 0.149 cm) and thickness(w_(th)) ranging from approximately 0.06 inches (0.152 cm) toapproximately 0.07 inches (0.178 cm). A center axis (A_(s)) of eachcooling slot 40 included in respective slot grouping forms apredetermined angle (θ_(AXIS)) with respect to the enter axis of anadjacent cooling slot 40, as discussed in greater detail below. In atleast one embodiment, the predetermined angle is approximately 24.00degrees.

The location of the cooling slots 40 may be formed on the thrust plate24 according to a plurality axes extending across the surface of thebody 26. Referring to FIG. 3, a horizontal axis (A_(H)) and a verticalaxis (A_(V)) extend across the body 26. The horizontal axis (A_(H))extends through a center of the thrust plate 24 and between a firsthorizontal point (θ₁) and a second horizontal point (θ₂). The firsthorizontal point (θ₁) is located at approximately 0 degrees with respectto the circumference of the outer edge. The second horizontal point (θ₂)is located at the outer edge approximately 180 degrees with respect tothe first horizontal point, i.e., 180 degrees from the 0 degrees point.The vertical axis (A_(V)) extends through the center of the thrust plate24 and between a first vertical point (θ₃) and a second vertical point(θ₄). The first vertical point (θ₃) is located at the outer edgeapproximately 90 degrees with respect to the first and second horizontalpoints (θ₁), (θ₂)., i.e., 0 degrees and 270 degrees, respectively. Thesecond vertical point (θ₄) is located at the outer edge at approximately270 degrees with respect to the first and second horizontal points (θ₁),(θ₂).

A plurality of leader axes are defined based on the horizontal andvertical axes (A_(H)), (A_(V)). The plurality of leader axes include afirst leader axis (A_(L1)), a second leader axis (A_(L2)), and a thirdleader axis (A_(L3)). The first leader axis (A_(L1)) is off-set at in aclock-wise direction at a first angle (X) with respect to the firsthorizontal point (i.e., 0 degrees) of the horizontal axis. A secondleader axis (A_(L2)) is off-set in a counter-clockwise direction at asecond angle (Y) with respect to the second horizontal point (i.e., 180degrees) of the horizontal axis. The third leader axis (A_(L3)) isoff-set in a counter-clockwise direction at a third angle (Z) withrespect to the first vertical point (i.e., 90 degrees) of the verticalaxis. In at least one embodiment, the first angle (X) is approximately21.00 degrees, the second angle (Y) is approximately 30.00 degrees andthe third angle (Z) is approximately 9.00 degrees.

The plurality of slot groupings are arranged on the thrust plate 24based on a respective leader axis. More specifically, a first slotgrouping 42 is arranged on the thrust plate 24 based on the first leaderaxis (A_(L1)), a second slot grouping 44 is arranged on the thrust plate24 based on the second leader axis (A_(L2)), and a third slot grouping46 is arranged on the thrust plate 24 based on the third leader axis(A_(L3)). Each slot grouping includes a lead cooling slot 48, which isthe basis for arranging the remaining cooling slots 40 in the respectiveslot grouping. The lead cooling slot 48 is spaced a predetermineddistance (d_(SLOT)) away from a respective lead axis. In at least oneembodiment, each lead cooling slot 48 is spaced approximately 0.915inches (approximately 2.324 cm) away from a respective lead axis in theclock-wise direction.

Referring to the first slot grouping 42, a first lead cooling slot 48 isformed on the thrust plate 24 such that a center axis (A_(S)) extendsthrough the center of the lead cooling slot 48 is approximately 0.915inches away from the first leader axis (A_(L1)). The three remainingcooling slots 40 of the first slot grouping 42 are formed such that therespective center axes (A_(S)) of each cooling slot 40 have an angle ofapproximately 24.00 degrees with respect to one another.

Referring to the second slot grouping 44, a second lead cooling slot 48′is formed on the thrust plate 24 such that the center axis (A_(S)) isapproximately 0.915 inches away from the second leader axis (A_(L2)).The three remaining cooling slots 40 of the second slot grouping 42 areformed such that the respective center axes (A_(S)) of each cooling slot40 have an angle of approximately 24.00 degrees with respect to oneanother.

Referring finally to the third slot grouping 46, a third lead coolingslot 48″ is formed on the thrust plate 24 such that the center axis(A_(S)) is approximately 0.915 inches away from the third leader axis(A_(L3)). Accordingly, the remaining cooling slot 40 of the third slotgrouping 46 is formed such that the respective center axis (A_(S)) hasan angle of approximately 24.00 degrees with respect to the third leadcooling slot (A_(L3)).

While various embodiments of the inventive concept had been described,it will be understood that those skilled in the art, both now and in thefuture, may make various modifications to the embodiments which fallwithin the scope of the claims which follow. These claims should beconstrued to maintain the proper protection for the invention firstdescribed.

What is claimed is:
 1. A thrust plate, comprising: an annular-shapedbody including a scalloped outer edge forming a first circumferencedefined by a first diameter; and a plurality of cooling slots formed ina first surface of the body and between each pair of adjacent scallops,a center of each cooling slot extending toward the center at a commonpredetermined angle with respect to one another.
 2. The thrust plate ofclaim 1, wherein the plurality of cooling slots are arranged on the bodyaccording to a plurality of slot groupings, each slot grouping includinga predetermined number of cooling slots.
 3. The thrust plate of claim 2,wherein the plurality of slot groupings include a first slot grouping, asecond slot grouping and a third slot grouping, the first and secondslot groupings each consisting of four cooling slots and the third slotgrouping consists of two cooling slots.
 4. The thrust plate of claim 3,wherein the scalloped outer edge defines a plurality of curved scallopsdefining a gap between each individual scallop, each scallop includingan outer eyelet formed therethrough.
 5. The thrust plate of claim 4,wherein a first plurality of outer eyelets have a different diameterthan a second plurality of outer eyelets.
 6. The thrust plate of claim5, wherein the first plurality of outer eyelets have a first eyeletdiameter to receive a respective first bolt to couple the thrust plateto a turbine housing and the second plurality of the outer eyelets havea second eyelet diameter smaller than the first diameter to receive arespective second bolt to couple the thrust plate to a bearing housing.7. The thrust plate of claim 6, wherein at least three of the gaps sizedlarger than the remaining gaps to define an alignment gap to positionthe thrust plate at a predetermined orientation when coupled via thefirst and second bolts.
 8. The thrust plate of claim 7, furthercomprising a plurality of alignment holes to receive a respective pindisposed therethrough to further align the thrust.
 9. The thrust plateof claim 8, wherein each slot extends between an open end formed at theouter edge of the and a curved end to define a slot length.
 10. Thethrust plate of claim 9, wherein the length ranges from 0.3 inches to0.4 inches, each slot having a thickness ranging from 0.06 inches to0.07 inches and a width ranging from 0.155 inches to 0.165 inches, thecommon angle being 24.00 degrees.
 11. A method of forming cooling slotsin a thrust plate, the method comprising: defining a horizontal axisthat extends radially from a center of the thrust plate; defining avertical axis that extends radially from the center of the thrust plate,the vertical axis being perpendicular to the horizontal axis; defining aplurality of leader axes that extend radially from the center of thethrust plate, the plurality of leader axes being off-set from at leastone of the horizontal and vertical axes by a predetermined angle;forming a plurality of slot groupings on a surface of the thrust platebased on the plurality of leader axes.
 12. The method of claim 11,wherein the defining a horizontal axis includes extending the horizontalaxis through a first horizontal point located at point of 0 degrees withrespect to a circumferential outer edge of the thrust plate, and secondhorizontal point located approximately 180 degrees with respect thefirst horizontal point.
 13. The method of claim 12, wherein the defininga vertical axis includes extending the vertical axis through a firstvertical point located approximately 90 degrees with respect to thefirst horizontal point, and a second vertical point located 270 degreeswith respect to the first horizontal point.
 14. The method of claim 13,wherein the defining a plurality of leader axes includes defining afirst leader axis off-set at a first predetermined angle in clock-wisedirection with respect to the first horizontal point, a second leaderaxis off-set at a second predetermined angle different from the firstpredetermined angle in a counter-clockwise direction with respect to thesecond horizontal point, and a third leader axis of set at a thirdpredetermined angle different from the first and second predeterminedangles, the third predetermined angle off-set-in a counter-clockwisedirection with respect to the first vertical point.
 15. The method ofclaim 14, wherein the forming the forming a plurality of slot groupingsfurther comprises forming a plurality of cooling slots according to arespective slot grouping.
 16. The method of claim 15, wherein theforming a plurality of slot groupings includes forming a first slotgrouping on the thrust plate based on the first leader axis, forming asecond slot grouping on the thrust plate based on the second leaderaxis, and forming a third slot grouping on the thrust plate based on thethird leader axis.
 17. The method of claim 16, further comprisingforming the cooling slots in each slot grouping such that the center ofthe cooling slots in a respective group is angled at a common angle withrespect to one another.
 18. The method of claim 17, wherein a center ofat least one cooling slot in each slot grouping is spaced from arespective lead axis by 0.915 inches.
 19. The method of claim 18,wherein the first predetermined angle is 21.00 degrees, the secondpredetermined angle is 30.00 degrees and the third predetermined angleis 9.00 degrees.